A direct alcohol fuel cell

ABSTRACT

A direct alcohol fuel cell having a proton exchange membrane (PEM) separating an anode section from a cathode section, which cathode section contains a cathode collection element electrically connected to a cathode catalyst, the cathode catalyst being in diffusive communication with a gaseous oxidant, and which anode section comprises an anode collection element electrically connected to an anode catalyst. The anode catalyst is in diffusive communication with a fuel supply. The PEM is structured to have a bottom and walls extending from the bottom to a containment distance into the cathode section, and the cathode catalyst is located within the containment distance from the bottom. The fuel cell is suited for a microelectronic device.

FIELD OF THE INVENTION

The present invention relates to a direct alcohol fuel cells (DAFC). TheDAFC and its assembly allow miniaturisation of the DAFC, which can beflexibly integrated with a microelectronic device.

PRIOR ART

In general batteries are becoming inadequate with respect to the powerrequirements for portable electronics. As the development of suchdevices strives towards smaller devices typically having the same orhigher power requirements the limited energy density of conventionalbatteries becomes critical. Examples of such devices are microelectronicdevices e.g. various microsensors, microengines, biomedicalmicrosystems, microelectromechanical systems (MEMS) etc. Hearing aidsare an extreme case of such portable devices with high demands on thepower source. Currently, high-end hearing aids working at largeamplifications have to have replaced the non-rechargeable zinc-air typebatteries every 1 to 8 days—depending on the type of the battery and thehearing aid. For example, a hearing aid will typically require about 1mW when no amplification is needed, and about 10 mW with moderateamplification with higher peaks of 15-20 mW or more when highamplification is required. In principle the Zn-air systems can becategorised as a non-rechargeable fuel cell, but are henceforth referredto as a battery to maintain the distinction towards proton conductingfuel cells.

The ideal power source for these types of devices would have largerenergy densities, re-chargeable capabilities and easy handling (whenrecharging), and DAFCs provide an alternative to Zn-air batteries. Puremethanol and ethanol have 27 and 32 times larger energy densities byweight, respectively, than Zn-Air batteries. When comparing energydensity by volume the numbers are 6 and 7 times, thus, ideally providingat least a 6-fold increase in operating time (when neglecting the systemvolume of the fuel cell). Furthermore, the fuel cell will be capable ofbeing recharged in a matter of minutes or even seconds by simplyreplenishing the fuel.

DAFCs are well-known in the prior art. In general terms, a DAFCtypically comprises a fuel cell stack containing a cathode collectionelement, a cathode electrode and catalyst, which, via a proton exchangemembrane (PEM), are separated from an anode electrode and catalyst, andan anode collection element. Fuel, i.e. alcohol, enters the anodesection and O₂, e.g. contained in ambient air, enters the cathodesection, and due to the selective diffusion of protons across the PEM,oxidation of the alcohol takes place at the anode and reduction of O₂takes place at the cathode so that an electrical potential is generatedbetween the anode and the cathode collection elements to allow the fuelcell to power an electrical circuit.

U.S. Pat. No. 7,947,408 discloses a fuel cell for burning a fuel gas,such as hydrogen, and aims to provide lighter weight fuel cells. U.S.Pat. No. 7,947,408 focuses on providing thinner collecting plates(separators and terminal plates), since the high voltage obtained fromstacked fuel cells, requires that the terminal plates are thick enoughto collect such high voltage and have a large thermal capacity, butobserve that thick collecting plates steal heat generated by adjacentend cells, and tend to adversely affect start-up characteristics at lowtemperature. U.S. Pat. No. 7,947,408 thus suggests to employ an outputterminal that is electrically connected to the collecting section andhas a thickness that is greater than the thickness of the collectingsection, and further that the collecting section and the output terminalare formed from a single sheet member. The output terminal is formed bybending the output terminal forming portion so that opposing faces comeinto contact and a first surface of the output terminal forming portionthat is positioned on a first side of a bend is flush with a secondsurface of the terminal forming portion that is positioned on a secondside of the bend.

However, the technology of U.S. Pat. No. 7,947,408 relates to hydrogenfuel cells providing high voltages and being of a scale inappropriatefor a fuel cell for a microelectronic device.

U.S. Pat. No. 5,543,241 discloses a cell structure for use in a fuelcell and the object is to provide a compact, high-voltage generatingfuel cell, which is easy to assemble and whose cell matrix can be easilychanged. The cell structure comprises a pair of insulating keep-platessandwiching the anode, the cathode and the PEM. However, the fuel cellis a hydrogen fuel cell and the high voltage, e.g. 120 V, is notrelevant for a fuel cell for a microelectronic device.

In contrast to the challenges faced by U.S. Pat. Nos. 5,543,241 and7,947,408, DAFCs for microelectronic devices, especially hearing aids,are faced with specific challenges relating to the available space forthe fuel cell. It is an aim of the present invention to address thisneed.

SUMMARY OF THE INVENTION

The present invention relates to a direct alcohol fuel cell (DAFC)comprising a proton exchange membrane (PEM) separating an anode sectionfrom a cathode section, which cathode section contains a cathodecollection element electrically connected to a cathode catalyst, thecathode catalyst being in diffusive communication with a gaseousoxidant, and which anode section comprises an anode collection elementelectrically connected to an anode catalyst, the anode catalyst being indiffusive communication with a fuel supply, wherein the PEM isstructured to have a bottom and walls extending from the bottom to acontainment distance into the cathode section, and wherein the cathodecatalyst is located within the containment distance from the bottom.

The DAFC may comprise an inner housing, and a PEM separating an anodesection from a cathode section, wherein the anode section contains ananode collection element electrically connected to an anode catalyst,which anode catalyst is in diffusive communication with a fuel supply,and wherein the cathode section contains a cathode collection elementhaving one or more ventilation holes, which cathode collection elementis electrically connected to a cathode catalyst, which cathode catalystvia the one or more ventilation holes is in diffusive communication witha gaseous oxidant, the inner housing having a bottom and walls extendingfrom the bottom to a length sufficient to contain the anode section, thePEM and the cathode section, the bottom and/or the walls having holesallowing fluid communication from a fuel supply to the anode section.

The DAFC may comprise a housing containing a PEM separating an anodesection from a cathode section, which anode section and which cathodesection are contained in the housing, the cathode section comprising acathode collection element electrically connected to a cathode catalyst,which cathode catalyst is in diffusive communication with a gaseousoxidant, and the anode section comprising an anode collection elementelectrically connected to an anode catalyst, and a pervaporationmembrane located at a spacing distance from the PEM, which pervaporationmembrane provides diffusive communication between the anode catalyst anda fuel supply, wherein the housing comprises one or more venting holesproviding fluid communication between the anode section and the ambientenvironment, which venting hole has or which venting holes have alargest dimension in the range of 25 μm to 300 μm, the venting holebeing located within the spacing distance.

The DAFC may comprise a housing containing a PEM separating an anodesection from a cathode section, which anode section and which cathodesection are contained in the housing, the cathode section comprising acathode collection element having one or more ventilation holes, whichcathode collection element is electrically connected to a cathodecatalyst, which cathode catalyst is in diffusive communication with agaseous oxidant, and the anode section comprising an anode collectionelement electrically connected to an anode catalyst, the DAFC comprisingan oleophobic filter covering the ventilation hole(s). The oleophobicfilter may be held in place using any appropriate means as desired.

In the context of the invention, the PEM and other optional membranesand layers in the anode section and/or the cathode section, the anodecatalyst, the anode collection element, the cathode catalyst and thecathode collection element may collectively be referred to as the “fuelcell components”, and either of these components may be referred to as a“fuel cell component”. The structure, e.g. the inner housing, containingthe fuel cell components may be referred to as a “power pack”.

The inner housing may be made from any material as desired. For example,the inner housing may be made, e.g. injection moulded, from anelectrically non-conductive thermoplastic elastomer. Thereby, the innerhousing provides electrical insulation between the fuel cell components,and between the fuel cell components and any exterior component.However, it is preferred that the inner housing is made from anelectrically conductive metal. Thereby, the inner housing can beelectrically connected to the anode collection element or the cathodecollection element to provide an anode terminal site or a cathodeterminal site, respectively. When the inner housing is electricallyconnected to the anode collection element, especially when the innerhousing serves as the anode terminal, assembly of the power pack issimplified. Likewise, when the inner housing is electrically connectedto the cathode collection element, especially when the inner housingserves as the cathode terminal, assembly of the power pack is alsosimplified.

The inner housing and/or the anode collection element may be made from athermoplastic elastomer appropriately coated with an electricallyconductive metallic surface or equipped with tracks of an electricallyconductive metal to allow the anode collection element to beelectrically connected with the anode catalyst. Correspondingly, thecathode collection element may be made from a thermoplastic elastomerappropriately coated with an electrically conductive metallic surface orequipped with tracks of an electrically conductive metal to allow thecathode collection element to be electrically connected with the cathodecatalyst

It is preferred that the inner housing is the anode collection element.In particular, it is preferred that the inner housing/anode collectingis made from a single piece of electrically conductive metal, e.g.stainless steel, optionally coated with gold. By employing the innerhousing as the anode collection element the volume of the power pack isreduced so that a DAFC with the power pack is especially suited formicroelectronic devices.

In another embodiment, the inner housing is the cathode collectionelement. it is preferred that the inner housing/cathode collecting ismade from a single piece of electrically conductive metal, e.g.stainless steel, optionally coated with gold. By employing the innerhousing as the cathode collection element the volume of the power packis reduced so that a DAFC with the power pack is especially suited formicroelectronic devices.

When the anode collection element is the inner housing the anodecollection element may also be referred to as an “anode cup”. In apreferred embodiment, the anode terminal site is provided as an anodecup. Correspondingly, the cathode collection element may be the innerhousing, and the cathode collection element may be referred to as a“cathode cup”. In a preferred embodiment, the cathode terminal site isprovided as a cathode cup.

The inner housing may have a length, e.g. a “Z-dimension”, to containthe anode section, the PEM and the cathode section so that the innerhousing can be considered to be a power pack. The length will typicallybe the minimal length to house the fuel cell components in order tominimise the volume of the power pack. The PEM may have a firstdimension, e.g. an “X-dimension”, and a second dimension, e.g. a“Y-dimension”, and these are typically of the same approximate size. Forexample, the X:Y ratio may be in the range of 1:10 to 10:1, e.g. 1:5 to5:1, or 1:2 to 2:1, e.g. X may be in the range of 2 mm to 30 mm, e.g. 5mm to 15 mm. When X of the PEM is in the range of 2 mm to 30 mm, e.g. 5mm to 15 mm, and the X:Y ratio is in the range of 1:2 to 2:1, theZ-dimension, or the length, of the inner housing may also be in therange of 1 mm to 15 mm, e.g. 1 mm to 2 mm, while the DAFC can provide apower output up to 30 mW, e.g. in the range of 1 mW to 10 mW. In anembodiment the length, i.e. the Z-dimension, of the inner housing is inthe range of 1 mm to 10 mm. The first and the second dimension of thePEM will typically be uniform over the length of the inner housing.

The inner housing may have a bottom and walls. The bottom will havedimensions to house the PEM, but the bottom is not limited to aparticular shape. For example, the bottom may be rectangular or square,e.g. with rounded corners, or the bottom may be circular or elliptical.The inner housing has holes allowing fluid communication from a fuelsupply to the anode section. The holes may be located in the bottomand/or in the walls depending on the location of the fuel supply. Theinner housing may have any number of holes as desired, e.g. 1 to 20, or5 to 10, and the holes may have any size and shape as desired. Forexample, the inner housing may have 3 to 8, e.g. 5, holes distributedover the bottom of the inner housing. The holes may be circular and havea diameter in the range of 500 μm to 2 mm.

It is preferred that the holes are in the bottom of the inner housingand the DAFC further contains an external housing with a fuel reservoir.For example, the external housing may also have a bottom and wallsextending from the bottom. The walls of the external housing may extendto house the power pack in the external housing, and the fuel reservoiris located at the bottom of the external housing. In another embodimentthe external housing contains the fuel reservoir but does not contain asubstantial portion of the power pack. For example, the external housingmay be considered to be a fuel reservoir that is attached to the powerpack.

The collection elements will be electrically connected to terminal sitesthat may be part of the DAFC or that may be external to the DAFC. Thecollection elements and the terminal sites are electrically conductingand both, alone or collectively, may also be described as electricallyconducting. Thus, the anode collection element and the cathodecollection element “collect” electricity and by being electricallyconnected to an external electrical circuit, e.g. via the terminalsites, the DAFC supplies electricity to the external electrical circuit.Thus, the anode collection element will be electrically connected to ananode terminal site, and the cathode collection element will beelectrically connected to a cathode terminal site. The terminal sitesallow that the DAFC is electrically connected to an external electricalcircuit that can be powered with the DAFC. The terminal sites aretypically located on or at an outer surface of the DAFC.

The cathode collection element and the anode collection element may havea generally planar structure, e.g. the collection elements may be“flat”, or the collection elements may deviate from a planar structure.For example, the external housing may have a shape to fit a specificpurpose, so that the external housing also has a surface deviating froma planar surface. In particular, the anode collection element may be theinner housing having a bottom and walls extending from the bottom to alength sufficient to contain the anode section, the PEM and the cathodesection, the bottom and/or the walls having holes allowing fluidcommunication from a fuel supply to the anode section. In anotherembodiment, the cathode collection element is made as a single piecetogether with a cathode terminal site extending from the cathodecollection element. For example, the cathode collection element with acathode terminal site may be a single flat piece with a bendable segmentbetween the cathode collection element and the cathode terminal site.

The DAFC may comprise a weld plate having one or more ventilation holes,which weld plate is welded to the housing to enclose the PEM, the anodesection and the cathode section. The weld plate holds the optionaloleophobic filter in place and further closes off the cell frompollution, except through the CO₂ hole and the ventilation holes, whenpresent. The housing may be the inner housing, e.g. an anode cup or acathode cup, or the housing may be the external housing, and the weldplate is preferably of the same material as the housing. When the weldplate is welded to an anode cup, the weld plate will provide an anodeterminal site, and in particular, the inner housing will also provide ananode terminal site. When the weld plate is welded to a cathode cup, theweld plate will provide a cathode terminal site, and in particular, theinner housing will also provide a cathode terminal site.

In other embodiments, the oleophobic filter is held in place byovermoulding of a polymer or gluing. Overmoulding of a polymer andgluing will protect the part of the cell between cathode collectionelement and the anode cup edge from outside contamination.

When the weld plate is welded to the anode cup, it is preferred that thecathode collection element is formed from one piece, e.g. a single pieceof metal, such as stainless steel, optionally coated with gold,including a cathode terminal site extending from the cathode collectionelement, and that the anode cup may contain, e.g. in a wall or in theoptional weld plate, an opening, e.g. a cut-out, for extending thecathode terminal through. Alternatively, the wall of the inner housing,e.g. the anode cup, may contain an opening for receiving a cathodeterminal site and establish an electrical connection from the cathodeterminal site to the cathode collection element. Correspondingly, anexternal housing to which the weld plate is welded may also contain anopening for allowing an electrical connection to be established with thecathode collection element.

When the DAFC has an anode cup with an opening for the cathode terminalsite or a cathode cup with an opening for the anode terminal site, theDAFC preferably contains electrically insulating layers or coatings,e.g. electrically insulating materials, such as a polyimide film, e.g.Kapton (as marketed by DuPont, Wilmington, Del., USA), to prevent directcontact, and thereby short-circuiting, between the cathode terminal siteand the anode terminal site. Neither the inner housing nor the externalhousing is required to have an opening for the cathode collectionterminal or the anode collection terminal to extend out of the innerhousing/external housing, but regardless of the presence of an opening,it is preferred that the DAFC comprises an electrically insulatingmaterial to prevent contact between the cathode terminal site and theanode terminal site.

By being welded to the housing, the weld plate provides a generallyfluid tight structure of the DAFC, and it is ensured that the onlyaccess to the cathode section is via the ventilation holes of the weldplate and the cathode collection element, e.g. through any filters ormembranes adjacent to the cathode collection element. In particular, theweld may follow the perimeter, e.g. the full perimeter, of the housing,whether the inner housing or the external housing.

The DAFC may also comprise a gasket, e.g. a silicone gasket, locatedalong the perimeter of the weld. A gasket employed with a DAFCcomprising a weld plate simplifies assembly of the DAFC with an externalmicrofluidic device, e.g. in an appropriate seating, provides an extralevel of fluid tight coupling between the DAFC and the seating.

The weld plate or a similar element, e.g. an overmoulded polymer orglue, allow the DAFC to contain additional layers outside the cathodesection. For example, the weld plate allows that an oleophobic filter islocated between the cathode collection element and the weld plate,although an oleophobic filter may also be used without a weld plate. Anoleophobic filter protects the cathode section from penetration ofliquids like sweat, oil and grease, e.g. through the ventilation holesof the cathode collection element. The DAFC may also contain ananion-exchange membrane in the cathode section, in particular betweenthe oleophobic filter and the cathode catalyst. An anion-exchangemembrane sequesters negative charged ions, e.g. chloride ions containedin sweat, that have entered the cathode section. Thereby, the DAFC canbe protected from penetration of sweat, oil, grease etc. and a DAFC isprovided that is especially suited for a microelectronic device to becarried close to the skin of an end-user, e.g. a hearing aid or a smartwatch. In an embodiment, the DAFC contains both an oleophobic filter andan anion-exchange membrane. It is preferred that the oleophobic filteris adjacent to the cathode collection element, e.g. the oleophobicfilter is in contact with the cathode collection element.

In a further embodiment, the DAFC contains a filter, e.g. a microfilterwith a pore size in the range of 0.1 μm to 25 μm, which microfiltercovers the ventilation hole(s) of the cathode collection element and theoptional weld plate. The microfilter may be between the weld plate, whenused, and the cathode collection element or the microfilter may bebetween the cathode collection element and the cathode diffusion layer,when used, or the cathode catalyst. A microfilter prevents particles,e.g. as determined by the pore size of the filter, from entering thecathode section. Thus, a more robust DAFC is provided by themicrofilter.

The DAFC has different sections, e.g. an anode section and a cathodesection, which are separated from each other. In the context of theinvention, the terms “separate”, “separated” or “separating” mean thatmass transfer between such sections is limited by the entity separatingthe sections. In the context of the invention, mass transfer may referto mass transfer across a membrane, within a section of the DAFC, e.g.within the anode section or within the cathode section, from the ambientenvironment to a section or from a section to the ambient environment.“Mass transfer” is to be understood broadly and covers at least fluidcommunication, mass transfer via diffusion (“diffusive communication”)mass transfer via convection, and mass transfer via pervaporation(“pervaporative communication”). For example, the PEM allows selectivetransportation of protons across the membrane. Likewise, “fluidcommunication” generally means that bulk transfer of fluid, i.e. aliquid and/or a gas, is possible, e.g. via a hole or an opening.

Mass transfer generally requires a driving force to affect the masstransfer. For example, a fuel may be supplied to a reservoir by pumping,and the high concentration of the fuel in the reservoir, e.g. 20 Mmethanol or more, will allow that the methanol evaporates into the anodesection, e.g. via the pervaporation membrane, due to the concentrationdifference between the reservoir and the anode section. When CO₂ isproduced in the anode section, the increase in pressure may push the CO₂away from the anode section e.g. via a venting hole. Furthermore, heatgenerated in the production of the CO₂ will create a convective flow ofthe CO₂. The combination of a pervaporation membrane and a venting holein the anode section allows that the DAFC is operated with a high, e.g.at least 10 M, concentration of methanol which gives a high energydensity. This in turn allows that the DAFC is operated passively, i.e.without actively moving fuel and waste components in the anode andcathode sections as relevant, and thereby a microscale DAFC, e.g. with aPEM having an area of 1 cm² or less, is possible. Thus, the combinationof the pervaporation membrane and the venting hole provides a passivemicroscale DAFC with a high energy density.

In the context of the invention “pervaporation” refers to a situationwhere a liquid is found on one side of a membrane that allows transferof molecules from the liquid through the membrane as a gas on the otherside of the pervaporation membrane. Correspondingly, “pervaporativecommunication” means that bulk transfer of fluid, in particular liquid,is not possible but that pervaporation of appropriate constituents ispossible. When the anode section of the DAFC contains a pervaporationmembrane the liquid alcohol fuel will be on one side of thepervaporation membrane, i.e. the fuel supply side, and that gaseous fuelwill be on the other side, i.e. the side facing the PEM. Thus, thepervaporation membrane prevents access of liquid fuel to the (anode)catalyst and thereby the orientation of the DAFC is not relevant. Thisis especially relevant for a DAFC used in a microelectronic device wornby an end-user, e.g. a hearing aid. A microelectronic device worn by anend-user will naturally follow the movements of the end-user so thatgravity may affect any direction of the DAFC, but when a pervaporationmembrane is included in the anode section the liquid fuel will beprevented from reaching the PEM, regardless of the orientation of theDAFC due to movement of the end-user. This advantage is especiallyrelevant when the DAFC also contains a venting hole in the anodesection. By preventing access of the liquid fuel to the section havingthe venting hole, i.e. the section within the spacing distance from thePEM, loss of liquid fuel via the venting hole is prevented while at thesame time allowing CO₂ to leave the anode section. Thus, the inventionprovides a DAFC for a hearing aid, which works independently of theorientation of the hearing aid.

Pervaporation may also be referred to as “diffusion”, and pervaporativecommunication may also be referred to as “diffusive communication”, andthe two terms may be used interchangeably. However, “diffusivecommunication” especially also refers to a situation where the samephases, e.g. liquid phases or gaseous phases, exist on both sides of themembrane. For example, a pervaporation membrane allows pervaporation offuel, especially methanol, from a side with a high concentration, e.g.the fuel supply side, to a side with lower concentration, e.g. the anodesection. An oleophobic filter allows diffusion of a gaseous oxidant fromthe ambient environment to the cathode section.

The DAFC has an anode catalyst and a cathode catalyst, which are indiffusive communication with a fuel supply and a gaseous oxidant,respectively. In the context of the invention, the term “catalyst”refers to any appropriate catalytic material, especially in the form ofparticles, e.g. platinum or mixtures of platinum and ruthenium. Thecatalyst may be deposited on or otherwise be in contact with furthermaterials. For example, the catalyst particles may be on a supportmaterial. When the catalyst, e.g. catalyst particles, are deposited on asubstrate, the substrate with the catalyst may be referred to as an“electrode” in the context of the invention. The catalyst will typicallybe found on a support, and when the catalyst is described as a “catalystlayer”, this generally refers to the support with the catalyst material.The catalyst may be together with a proton conductor, e.g. Nafion, beplaced on a gas diffusion substrate, e.g. carbon paper or carbon cloth,which may also be referred to as an electrode or a gas diffusionelectrode. The appropriate catalyst particles, e.g. platinum orplatinum-ruthenium particles, are preferably located on a supportmaterial with a high specific surface area, e.g. a carbon material, suchas carbon nanoparticles, carbon nanotubes, carbon fibres, etc. A supportmaterial of a high specific surface area may distribute a liquid overthe high specific surface area so that the liquid is more easilyevaporated. A support is not required for the catalyst particles andthese may also be placed on the PEM or another material having protonconducting properties.

Both the anode section and the cathode section may further contain oneor more diffusion layers, e.g. a layer of carbon fibres, that, togetherwith the support material of the respective catalysts, promote diffusionof fuel, e.g. methanol, to the anode catalyst and O₂ to the cathodecatalyst. It is also contemplated that the catalyst particles may beintegrated with the diffusion layer. The diffusion layer may also bereferred to as a “water management layer” (WML). A WML typically alsoaffects the water retention of the system.

The DAFC contains a membrane, e.g. at least a PEM. In the context of theinvention the term “membrane” is to be understood broadly, and anymembrane providing the desired functionality can be used. In the contextof the invention a membrane is non-porous, and the membrane isconsidered to prevent fluid communication but to generally allowdiffusion, e.g. pervaporation, through the membrane while optionallyalso preventing diffusion of specific constituents.

The DAFC contains a PEM that separates the anode section from thecathode section, but the DAFC may also contain other membranes. Amembrane may be a polymeric material with a backbone optionally carryingrelevant groups providing a functionality. Typical membrane materialsare silicone, polyether ether ketone (PEEK), and fluoropolymers. Forexample, a membrane, especially a pervaporation membrane, may have afluoropolymer backbone of poly-tetrafluoroethylene (PTFE), and the PTFEmay optionally have perfluoroether pendant side chains terminated bysulphonic acid groups to provide negative charges. A PTFE backbone willgenerally prevent liquids from passing through the membrane whileallowing diffusion through the membrane. For example, sulphonic acidgroups on a PTFE membrane, e.g. a Nafion membrane, may attract watermolecules that diffuse into the membrane to improve the protonconducting properties of the membrane.

The DAFC may contain a pervaporation membrane that is permeable togasses but impermeable to liquids. A pervaporation membrane may also bereferred to as a “semipermeable membrane”. The pervaporation membranemay for example be made from silicone, PEEK, and/or PTFE. Thepervaporation membrane may also comprise charged groups providing ionexchange capabilities to the pervaporation membrane. For example, thepervaporation membrane may be or comprise a PTFE backbone withperfluoroether pendant side chains terminated by sulphonic acid. TheDAFC may also contain uncharged pervaporation membranes that generallyallow diffusion through the membrane while preventing bulk transfer ofliquid.

Membranes based on hydrogels may also be used. A hydrogel is generallyconsidered to allow diffusion, e.g. easy diffusion, of H₂O molecules, sothat a hydrogel may be permeable, e.g. via diffusion, to aqueous liquidsor other hydrophilic liquids. A hydrogel may contain positively ornegatively charged groups for sequestering ions of the opposite chargefrom aqueous liquids passing through the membrane, i.e. the hydrogel maybe an ion-exchange membrane.

Furthermore, the DAFC may contain a cation-exchange pervaporationmembrane, e.g. a negatively charged pervaporation membrane, e.g. apolymer with a PTFE backbone carrying perfluoroether pendant side chainsterminated by sulphonic acid groups, that allows diffusion of fuel andwaste components to or from the electrodes while preventing diffusion ofpositively charged ions, in particular metal ions. Likewise, the DAFCmay contain an anion-exchange membrane, e.g. polymeric anion-exchangemembrane or a hydrogel membrane with positively charged groups, thatallows diffusion of fuel and waste components to or from the electrodeswhile preventing transfer of negatively charged ions, in particularchloride ions. Ion-exchange membranes may also be referred to as“charged membranes”, e.g. “positively charged membranes” or “negativelycharged membranes” and the terms may be used interchangeably. In thecontext of the invention, a membrane is considered to be charged, e.g.positively charged or negatively charged, when the membrane hascovalently attached groups of the corresponding charge; the overallcharge of the membrane will be balanced by oppositely charged ions inthe fluid in contact with the membrane but the membrane may still bereferred to as “charged”. A cation-exchange membrane will typically be“loaded” with hydrogen ions so that when further hydrogen ions areapplied to the cation-exchange membrane it will appear to be permeablyto hydrogen ions. Thus, a cation-exchange membrane may be “protonconductive” in the context of the invention.

In an embodiment, the cathode section comprises an anion-exchangemembrane. The anion-exchange membrane is preferably placed between thecathode catalyst and the cathode collection element, e.g. between thecathode catalyst, which may be deposited on a support so at to provide acathode electrode, and the cathode WML when present. Any membranematerial is relevant for the anion-exchange material, but in a specificembodiment the anion-exchange membrane is a PEEK membrane with positivecharges, e.g. from quaternary or other amine groups. Other relevantmembrane materials comprise polyester or PTFE. The thickness of theanion-exchange membrane may be in the range of 10 μm to 500 μm, e.g. 50μm to 200 μm, and the ion-exchange capability may be in the range of 0.5mmol/g to 2 mmol/g. An exemplary anion-exchange membrane is thepolyester membrane marketed as fumapem FAA-3-30 (Fumatech BWT GmbH,Bleitigheim-Bissingen, Germany), which has a thickness in the range of27 μm to 31 μm and, an ion-exchange capacity of about 1.6 mmol/g. Ahydrogel based anion-exchange membrane is also contemplated. Theanion-exchange membrane generally allows easy diffusion of water throughthe membrane while the positive charges provide an anion-exchangefunction so that negative ions, e.g. Cl⁻, will be sequestered in theanion-exchange membrane and prevented from reaching the cathodecatalyst. An anion-exchange membrane is especially suited for amicroelectronic device worn by an end-user, e.g. a hearing aid or asmart watch, where the microelectronic device may come into contact withsweat from the end-user, since the anion-exchange membrane will protectthe DAFC from penetration of sweat into the cathode section.

In the context of the invention a membrane is non-porous, e.g. any poresin the membrane will be in the nanometer range. The DAFC may alsocontain filters, e.g. an oleophobic filter. A “filter”, in contrast to amembrane, is porous and has a defined pore size, especially larger thanthe nanometer range. A filter, e.g. an oleophobic filter, as used in theDAFC may also comprise further openings that are larger than the poresize. An example of an oleophobic filter is a porous, e.g. microporous,perfluoro derivatised polymeric material, e.g. PTFE.

A DAFC will produce CO₂ in the anode section and for many types of DAFCit will use H₂O. In the cathode section the DAFC will produce H₂O andmay also produce CO₂ because of crossover of fuel from the anode side tothe cathode side. CO₂ can diffuse away from the respective sections, butin general mass transfer of CO₂ will typically also be driven bypressure and moreover the oxidation of carbon containing species to CO₂will produce heat so that mass transfer of CO₂ may also be viaconvection. Thus, since the pressure increases in the cathode sectionwhen CO₂ is produced, CO₂ will be pushed away from the cathode catalyst,e.g. via ventilation holes in the cathode collection element. The DAFCespecially produces CO₂ in the anode section, and CO₂ produced in theanode section may diffuse away from the anode section via the PEM or viathe pervaporation membrane. However, when the DAFC comprises a ventinghole located in a housing, the venting hole advantageously allows theCO₂ to be removed from the anode section due to build-up of pressure butalso due to convection and via diffusion. In particular, the removal ofCO₂ through the venting hole is more efficient than diffusion throughthe PEM. A single venting hole is sufficient for allowing removal of CO₂from the anode section, and in particular, a single venting holeprevents a flow into the anode section due to the higher pressure in theanode section compared to the pressure in the ambient environment. Forexample, when the DAFC comprises 2 or more ventilation holes, it iscontemplated that a different flow profile for the CO₂ in the anodesection may occur due to convection in the anode section so that a flowmay be created through the anode section, e.g. CO₂ exits via oneventilation hole whereas another ventilation hole allows a flow from theambient environment into the anode section. In a preferred embodiment,the DAFC contains only a single venting hole.

The venting hole has a largest dimension in the range of 25 μm to 300μm, but it may have any shape as desired. For example, the venting holemay be elliptical with a minor axis and a major axis, e.g. with a lengthin the range of 25 μm to 300 μm, where the length of the minor axis isin the range of 50% to 100% of the length of the major axis. Inparticular, the venting hole may be circular with a diameter in therange of 25 μm to 300 μm, e.g. about 50 μm. It is also contemplated thatthe venting hole may be rectangular, e.g. with a first dimension havinga length of 50% to 100% of a second dimension. In particular, arectangular venting hole may be square. Thus, the venting hole may besquare with a diagonal in the range of 25 μm to 300 μm, e.g. about 50μm. When the venting hole has a largest dimension in the range of 25 μmto 300 μm, the inventors have surprisingly found that an optimal balanceis reached between removal of CO₂, prevention of entry of O₂ into theanode section, and prevention of loss of alcohol fuel. Insufficientventing of CO₂, e.g. when a venting hole smaller than 25 μm is present,or when no venting hole is present, will result in a pressure build upwhich limits the max power and increases the risk of flooding, Moreover,the insufficient venting of CO₂ that occurs when no venting hole or atoo small venting hole is present will also reduce the maximum poweravailable from the DAFC. When the DAFC has a venting hole with adimension larger than 300 μm, CO₂ will be removed efficiently from theanode section, but the anode section will also lose fuel through theevaporation hole at a rate sufficiently high to reduce the operatingtime and require refueling too soon. Furthermore, when the ventilationhole has a diameter, larger than 300 μm, O₂ may enter the anode section,in particular when the DAFC is running low on fuel, which will shortenthe lifetime of the DAFC. Thus, by using a ventilation hole, e.g. acircular ventilation hole, as defined above, the life time of a DAFC canbe increased. Thus, the optimal size of the venting hole is a compromisebetween sufficient venting and a too open structure, for which theoptimum is dependent on max power and size of the cell. For the cellpresented in this text a venting hole of 40-100 μm has proven a goodcompromise. When the venting hole has a largest dimension in the rangeof 25 μm to 200 μm, e.g. in the range of 40 μm to 100 μm, in particularwhen the largest dimension is in the range of 40 μm to 60 μm, theventing hole provides an optimal compromise between sufficient ventingand a too open structure, and both the fuel loss and the entry of O₂into the anode section will be insignificant.

In a specific embodiment, the DAFC has 2 or more ventilation holes. Inparticular, the DAFC may have 2 ventilation holes with a largestdimension in the range of 25 μm to 100 μm. When the DAFC has 2 or moreventilation holes, more efficient removal of CO₂ is possible, especiallywhen the 2 or more ventilation holes are distributed, e.g. evenlydistributed, on the surface of the housing.

The ventilation hole or ventilation holes allow fluid communication withthe ambient environment, which may contain particles, e.g. dust, of asize small enough to enter the anode section. However, due to thepressure build-up in the anode section penetration of particulatecontaminants into the anode section is generally avoided. However, it ispreferred that the DAFC comprises 2 or more small ventilation holes witha largest dimension in the range of up to 75 μm, e.g. circularventilation holes with diameters in the range of 40 μm to 60 μm. Thesmaller the cross-sectional area of the ventilation holes, the largerthe flow velocity of CO₂ exiting the anode section and thereby thesmaller the risk that unwanted particles enter the anode section. Thesame effect is relevant to prevent entry of O₂ into the anode section.

In an embodiment, the venting hole or venting holes comprise a filter,e.g. a filter covers the venting hole. A filter, e.g. with a pore sizein the range of 0.1 μm to 20 μm, will limit the entry of particles witha size corresponding to the pore size of the filter and prevent entry ofparticles larger than the pore size. The filter typically has athickness in the range of 10 μm to 500 μm. The inventors havesurprisingly found that even though the filter provides a pressure dropover the filter, a filter, e.g. with a pore size in the range of 0.1 μmto 10 μm, does not negatively affect the removal of CO₂ from the anodesection. In a specific embodiment, the filter is an oleophobic filter,e.g. a filter comprising a PTFE polymer backbone with pores in the sizerange of 0.1 μm to 20 μm and a thickness in the range of 50 μm to 500μm. An oleophobic filter limits penetration of liquids and furtherlimits penetration of oil and grease into the anode section withoutaffecting removal of CO₂ from the anode section.

When the DAFC has a venting hole, the pervaporation membrane may be of aPTFE-type as defined above, and it may have negatively charged groups,e.g. the PTFE may have perfluoroether pendant side chains terminated bysulphonic acid groups, but the charges do not influence the function ofthe venting hole. The pervaporation membrane, regardless of the presenceof charges, functions together with the venting hole, and the balancebetween removal of CO₂ and prevention of loss of fuel is improved when aventing hole is employed in combination with the pervaporation membrane.However, it is also contemplated that the venting hole may be usedwithout a pervaporation membrane. Regardless of the presence of apervaporation membrane, the spacing distance will typically be in therange of 100 μm to 300 μm.

The venting hole is located between the PEM and the pervaporationmembrane, i.e. the spacing distance from the PEM. When the venting holeis located within the spacing distance, the venting hole is availablefor removal of CO₂ produced in the anode section. Thus, in a preferredembodiment the DAFC has a venting hole, e.g. a circular venting hole,with a largest dimension, e.g. diameter, in the range of 30 μm to 80 μm,which venting hole is located at a distance corresponding to 30% to 70%of the spacing distance as measured from the PEM. In this embodiment,the optimal balance between removal of CO₂ from the anode section,prevention of entry of O₂ into the anode section, and prevention of lossof fuel, in particular methanol, is obtained.

The DAFC may also comprise a spacer insert layer between thepervaporation membrane and the PEM, i.e. between the pervaporationmembrane and the anode catalyst, or between the pervaporation membraneand the optional anode diffusion layer. A spacer insert layer ispreferably electrically conducting, e.g. it may be a sheet of stainlesssteel, optionally coated with gold, and it may have one or more holeswith a total area in the range of 5% to 90%, e.g. 10% to 80% or 25% to50%, of the total area of the spacer insert layer. The spacer insertlayer will typically have a total area corresponding to the availablearea, e.g. as defined by the cross-section of an inner housing. The holeor holes in the spacer insert layer especially promote transfer, e.g. byconvention, diffusion or pressure differences, of CO₂ away from theanode catalyst and therefore the venting hole functions more efficientlywhen a spacer insert layer is employed. When a spacing distance of atleast 50 μm is used between the pervaporation membrane and the PEM, itis preferred that the spacer insert layer is used. Thus, the spacingdistance will correspond to the thickness of the anode catalyst, theoptional anode diffusion layer, and the spacer insert layer. The spacerinsert layer will typically have a thickness in the range of 50 μm to200 μm, e.g. 75 μm to 125 μm, such as about 100 μm.

The venting hole may be located in a housing of the DAFC. The housingmay be an inner housing, in particular an anode cup or a cathode cup, orthe housing may be an external housing. The venting hole will be in thewall of the housing, and when the DAFC has both an inner housing, e.g.an anode cup or a cathode cup, and an external housing the venting holewill be in the inner housing. In particular, it is preferred that theexternal housing provides a fuel reservoir and that the external housingis attached to the inner housing without covering the location of theventing hole or venting holes in the inner housing. However, theexternal housing may have a hole aligned with the venting hole in orderto provide fluid communication between the anode section and the ambientenvironment. The hole in the external housing is not limited and may beany size equal to or larger than the venting hole. In particular, whenthe external housing is adjacent to, e.g. in electrical connection or inelectrically insulated contact with, the inner housing, the venting holein the inner housing is preferably aligned with the hole in the wall ofthe external housing.

In another embodiment, there is a distance, e.g. a normal distance inthe range of 10 μm to 200 μm, between the inner housing and the externalhousing, and the venting hole in the inner housing may be aligned with ahole in the wall of the external housing, or there may be a hole in theexternal housing that is not aligned with the venting hole in the innerhousing.

Regardless of the location of the venting hole in the housing, thepresence of a venting hole improves the general mass transfer, e.g. ofalcohol fuel, such as methanol, by aiding in the removal of CO₂ from theanode section, and thereby the venting hole can be considered to improvethe maximum power of the DAFC. Without being bound by theory, thepresent inventors believe that the effect obtained from thepervaporation membrane in the anode section in allowing the DAFC to beoperated with passive mass transfer, i.e. without active pumping, e.g.of alcohol fuel and waste components, is also improved. Thus, a ventinghole and a pervaporation membrane in the anode section allow the DAFC tobe used with passive mass transfer and without active pumping. However,the fuel reservoir, when present, may still be filled using activepumping which does not provide any effect on the mass transfer in theanode section and the cathode section. A DAFC supplied with fuel from anexternal supply is considered to be a “passive” fuel cell in the contextof the invention. Likewise, the DAFC may employ active removal of wastegasses from the outside of the housing; this embodiment is alsoconsidered to be a passive fuel cell.

The fuel cell components of the DAFC are generally arranged in layers,and each layer may correspond to an available surface area. For example,the DAFC may have a surface area of the PEM, a surface area of the anodesection and a surface area of the cathode section. The different surfaceareas may be of the same or different sizes. Elements constituting alayer will typically fill the area available for the layer. Inparticular, catalyst layers will fill the available area in order tooptimally use the available area. Likewise, any membrane included in theDAFC, whether in the anode section or the cathode section, willtypically also fill the available area.

The DAFC may comprise an oleophobic filter, which covers the ventilationhole(s) of the cathode collection element. Oleophobicity, andcorrespondingly also hydrophobicity, may be defined in terms of contactangles between a material and an appropriate solvent, i.e. an “oil like”solvent for oleophobicity and a “water like” solvent for hydrophobicity.Thus, an appropriate oil-like solvent is n-hexadecane, and when thecontact angle between n-hexadecane and the surface of the material is inthe range of 60-80° the material is considered to be oleophobic. Forexample, for PTFE n-hexadecane has a contact angle of about 65° so thatPTFE is oleophobic. Any material, in particular any polymer, with acontact angle between n-hexadecane and the material of at least 60° isoleophobic in the context of the invention and may be used for theoleophobic filter. The oleophobic filter may be on either side of thecathode collection element. When the oleophobic filter is between thecathode collection element and the cathode electrode, the oleophobicfilter is designed to allow that the cathode collection element iselectrically connected to a cathode catalyst. Any appropriate materialmay be used for the oleophobic filter. For example, the oleophobicfilter may comprise a polymeric backbone providing a sheet or the likeof a thickness in the range of 20 μm to 500 μm, e.g. 100 μm to 200 μm,and having pores in the size range of 0.1 μm to 20 μm, e.g. 0.1 μm to1.0 μm. The polymeric backbone may be any polyolefin backbone or afluoropolymer backbone. An especially preferred backbone is afluoropolymer, such as PTFE. In an embodiment, the backbone does notcomprise any charged groups, e.g. acid groups or amine groups. Theperfluoro groups of the polymer backbone will minimise penetration ofliquid water through the pores of the filter, even when the water isapplied at a pressure higher than normal atmospheric pressure, while thepores allow transfer of gaseous molecules. The perfluoro groups furtherlimit the penetration of oils and oil like liquids into the cathodesection. Another appropriate material is microporous polyvinylidenefluoride with thicknesses and pore sizes in the range of 20 μm to 500 μmand 0.1 μm to 20 μm, respectively. In general, when a polymer comprisesfluoro-groups it is preferred that fluorine atoms are found onsubstantially all available sites, e.g. that hydrogen atoms aresubstituted with fluorine atoms.

The oleophobic filter may be placed so that the cathode catalyst is indiffusive communication with a gaseous oxidant. Thus, the inner housingtogether with the oleophobic filter can be considered to form an “outersurface” of the power pack. Thereby, the entry points into the powerpack will be provided by the holes, e.g. for fuel, in the inner housingand the oleophobic filter for gaseous oxidant and waste components.Thus, the oleophobic filter will hinder liquids, i.e. both hydrophilicand hydrophobic liquids, from entering into the cathode section. Byproviding a hindrance for liquids the oleophobic filter protects theinterior, especially the cathode section, from contaminants from theambient environment.

The optional oleophobic filter is especially advantageous when thecathode section of the DAFC also contains an anion-exchange membrane.The oleophobic filter generally hinders liquids, and thereby also themajority of negative ions from entering the cell, and the few that doenter can be sequestered in the anion-exchange membrane. Thus, theoleophobic filter improves the function of an anion-exchange membrane.The combination of the oleophobic filter and the anion-exchange membraneare therefore especially suited for a DAFC to be used in close contactwith an active surface, such as the skin of a human being, and the DAFCaccording to the invention is therefore especially suited for a hearingaid or similar devices, e.g. a smart watch or a smart phone. Theoleophobic filter will minimise penetration of liquids, e.g. sweat, intothe cathode section so that when the DAFC comprises both an oleophobicfilter and an anion-exchange membrane, the amount of chloride ions, e.g.from sweat, reaching the anion-exchange membrane will be minimised, andthereby the life time of the anion-exchange membrane will be extendedcompared to a DAFC not having the oleophobic filter. Correspondingly,the anion-exchange membrane extends the life time of the DAFC byminimising or preventing penetration of chloride ions into the cathodesection. Thus, the invention provides a DAFC for a microelectronicdevice to be worn by an end-user, e.g. a hearing aid or a smart watch,having an increased longevity.

In an embodiment the oleophobic filter has one or more openings alignedwith the ventilation holes of the cathode collection element and/or theventilation holes of the weld plate when used. The openings allow moreefficient transfer of especially H₂O as liquid, from the cathode sectionto the ambient environment. DAFCs employ electrochemical reactions andexternal influences may affect the speed of the electrochemicalreaction, and thus the output, which means that there is a variation inhow much water is produced. When more H₂O is produced than can becontained in the air (saturation) the H₂O condenses in the cell asliquid water, and this liquid water front can cause a blockade in thesupply of air to the reaction. Occurrence of liquid H₂O may causeflooding of the DAFC, so that by including openings in the oleophobicfilter, the risk of flooding is minimised. The inventors havesurprisingly found that when the oleophobic filter comprises openings,e.g. a slit for each ventilation hole, the openings allow that the DAFCis operated at a high relative humidity. Thereby the openings in theoleophobic filter are especially relevant for a microelectronic deviceto be worn by an end-user, e.g. a hearing aid or a smart watch, wheresweat from the end-user may create local areas of high humidity in thevicinity of the microelectronic device. The openings are aligned withthe ventilation holes of the cathode collection element and also of theoptional weld plate, when present. For example, the oleophobic filtermay have a single opening or it may have a number of openings up to thenumber of ventilation holes. It is also possible that the oleophobicfilter has more than one opening aligned with a single ventilation hole.The opening may have any form desired, but it is preferred that theopening has the form of a slit in the oleophobic filter. It is furtherpreferred that the slit has a continuous form, e.g. that sections of theslit do not cross each other. When the opening is a slit, it ispreferred that the slit follows the longest line available from theshape of the ventilation hole. For example, when the ventilation hole isrectangular or square, the slit may follow the diagonal of theventilation hole, and when the ventilation hole is circular, the slitmay follow the diameter of the ventilation hole. Thereby, the optimalbalance for hindering penetration of liquids while still allowing liquidwaste H₂O and gaseous oxidant through the oleophobic filter is obtainedeven though the oleophobic filter otherwise serves to hinder penetrationof liquids.

The PEM may be considered a central layer immediately adjacent to thecathode catalyst and the anode catalyst in the cathode section and theanode section, respectively. The catalyst layers may be prepared fromdepositing an “ink” with catalyst particles, optionally on a supportmaterial, onto the PEM or a carbon substrate, e.g. CeTech carbon clothW1S1009. The ink may be made of catalyst material, e.g HiSPEC 13100 fromjohnson matthey, a proton conductor, e.g. nafion, and other optionalmaterials, e.g. PvP, in a solvent that can consist of any combination ofa number of solvents, e.g. water, IPA, methanol etc. When the catalystink is deposited onto the PEM, it is called a catalyst coated membraneor CCM. When the catalyst ink is deposited onto a carbon substrate,which is the method chosen in the work presented here, it is called agas diffusion electrode or just electrode.

The catalyst layers, e.g. the electrodes, may each face one or moreadditional diffusion layers, i.e. an anode diffusion layer and a cathodediffusion layer, that may be a carbon based fibrous material. Thediffusion layers may also be referred to as the “anode WML” or the“cathode WML”, respectively, and the anode and the cathode WML may be ofthe same material. The catalyst layer and the diffusion layer may alsobe integrated into one layer. The diffusion layers may further comprisesections, e.g. surface sections, with additional functionalities. Forexample, a WML may have a microporous layer of carbon particles and themicroporous layer and/or the carbon fibres may have a hydrophobictreatment, e.g. a PTFE-derivatised surface. The PTFE surface can affectthe mass transfer balances of the system, e.g. help push water from thecathode side to the anode side and help prevent flooding on the cathodeside.

In the DAFC of the invention, a PEM is located between the anodecatalyst and the cathode catalyst. Any material, e.g. the material knownunder the trademark “Nafion”, that allows selective transportation ofprotons across the membrane may be used in the DAFC. The thickness ofthe PEM can be chosen freely, but the thickness will typically be in therange of 10 μm to 1 mm, e.g. from 50 μm to 500 μm, or from 100 μm to 250μm. The PEM is structured to have a bottom and walls extending from thebottom to a containment distance into the cathode section, and whereinthe cathode catalyst is located within the containment distance from thebottom. The containment distance will typically be up to 5 mm, e.g. inthe range of 200 μm to 2 mm. The PEM is preferably made from a singlepiece of the membrane that has been shaped to have the bottom and thewalls, and in this embodiment the PEM may be referred to as a “PEM cup”.By containing the cathode section in a PEM cup, the DAFC will have amore compact design than is possible when the PEM has a planar shape,and moreover assembly of the DAFC is simplified. In particular, the PEMcup also functions as a gasket separating the anode section from thecathode section, and the PEM cup will also be both an electricalinsulator and provide mechanical support to ensure optimal assembly.Thus, the PEM cup simplifies assembly of the power pack and allows ahigher power output from a DAFC compared to a DAFC not having a PEM cup.

With the PEM cup it is possible to obtain a more efficient use of thehousing area, which is important for the overall performance, and thePEM cup can be considered to be the minimal mechanical structurerequired to act as a gasket separating the anode side from the cathodeside. Thus, the PEM cup optimises the power density in the DAFC.

The PEM may be a Nafion, e.g. Nafion 117, membrane and the PEM cup istypically formed using thermo- and/or vacuum forming, e.g. starting froma Nafion membrane of a thickness in the range of 90 μm to 200 μm. Forexample, the PEM cup may be hot-pressed into shape prior to assembly ofthe power pack. When the PEM cup has been made using thermo- and/orvacuum forming the PEM cup will be a continuous single piece of materialwithout seams or the like, which further minimises the volume of theDAFC or the power pack.

The PEM cup may advantageously be used with a DAFC having an innerhousing, in particular an inner housing that is also the anodecollection element, e.g. an anode cup, or an inner housing that is alsothe cathode collection element, e.g. a cathode cup. When the PEM cup isused with an anode cup, the volume of the DAFC is minimised compared towhen the PEM cup is used in another design of the DAFC, or when theinner housing contains a PEM of another shape, e.g. a flat or planarPEM. When the PEM cup is used with an inner housing, the containmentdistance will be shorter than the length of the inner housing, andcorrespondingly the dimensions, e.g. the “X-dimension” and the“Y-dimension” of the bottom of the PEM cup, will be smaller than thedimensions of the inner housing. However, due to the electricalinsulation of the PEM cup, the PEM cup may be in contact with the innerwalls of the inner housing, also when the inner housing is an anode cupor the cathode cup.

In a preferred embodiment, the DAFC has a PEM cup and a cathodecollection element with a cathode terminal site formed as a singlepiece, e.g. a single piece of metal. For example, the cathode collectionelement and the cathode terminal site may be a single metallic piece, ora single piece made from a thermoplastic polymer with a coating of anelectrically conducting metal or tracks of an electrically conductingmetal. In particular, the cathode collection element with the cathodeterminal site may have a bendable segment between the cathode collectionelement and the cathode terminal site. In this embodiment, the cathodecollection element with the cathode terminal site is contained in thePEM cup, i.e. in the cathode section, and the wall of the PEM cup mayhave an opening, e.g. a cut-out, through which the cathode terminal siteextends. It is also possible for the cathode terminal site to extendabove the wall of a PEM cup not having an opening. In both embodiments,the DAFC may have a cathode terminal at a surface different from thesurface having the cathode collection element so that the access to thecathode collection element, and thereby also the cathode catalyst, for agaseous oxidant and for waste from the fuel cell. When the DAFC has aPEM cup with an opening, e.g. a cut-out, and a cathode collectionelement with a cathode terminal site extending through the opening, thevolume of the DAFC is minimised.

When the PEM cup has an opening, e.g. a cut-out, for a cathode terminalsite, the DAFC may advantageously have an inner housing, in particularan anode cup, which has an opening, e.g. a cut-out, in a wall, whichopening is aligned with the opening of the PEM cup. Thereby, the totalvolume of the DAFC is minimised even further, and moreover the terminalsite will be located at a surface of the inner housing, e.g. the anodecup, pointing away from the surface having the cathode collectionelement.

The DAFC can be considered to burn an alcohol, typically methanol, sothat the DAFC employs, in addition to the alcohol fuel, a gaseousoxidant, e.g. O₂, especially O₂ contained in ambient air. Other gaseousoxidants are also contemplated. The reaction between O₂ and the alcoholwill create CO₂ and H₂O, e.g. gaseous H₂O, as waste components. Theventilation holes in the cathode collection element and the optionalweld plate allow that waste products can easily leave the DAFC and thatgaseous oxidant, e.g. ambient atmosphere, can easily enter the cathodesection.

The selective diffusion of protons across the PEM allows that anelectrical potential is created between the anode collection element andthe cathode collection element, e.g. as represented by the respectiveterminal sites. The anode collection element is therefore electricallyisolated from the cathode collection element, including the respectiveterminal sites. The electrical isolation may be obtained using anyelectrically insulating material, e.g. a polymer.

The DAFC has a cathode collection element having ventilation holes. Itis to be understood that the “ventilation holes” may be only a singlehole or a plurality of holes. The cathode collection element iselectrically conducting and preferably made from a single piece ofmetal, e.g. a stainless steel, optionally coated with a layer of gold.It is preferred that the cathode collection element and the cathodeterminal site are a single piece. Likewise, when the DAFC has a weldplate, the weld plate also has ventilation holes. It is preferred thatthe ventilation holes of the optional weld plate are aligned with theventilation holes of the cathode collection element, e.g. that the weldplate and the cathode collection element have the same number ofventilation holes at the same locations relative to the area of thecathode section.

It is preferred that the terminal sites, i.e. the anode terminal siteand/or the cathode terminal site, are located on an outer surface of theDAFC, e.g. on an outer surface of an external housing containing theDAFC. It is especially preferred that the terminal sites are located ata different surface than the surface with the cathode collectionelement, and the optional weld plate, having ventilation holes. Thereby,it is possible for the DAFC to be in electrical contact with amicroelectronic component or a further DAFC of the invention, withoutneeding certain structural features that can block the ventilationholes, e.g. a seating or wall or the like of the microelectroniccomponent or the further DAFC, and whatever is in front of theventilation holes can be freely designed, e.g. ribs giving a controlledamount of ventilation to the cell. A further advantage of employing acathode terminal at another surface than the surface having the cathodecollection element is that pollution of the cathode section isminimised. In particular, establishing contact between the surfacehaving the cathode collection element and an external unit, e.g. amicroelectronic device, the act of establishing the contact can forcecontaminants, e.g. particles, into contact with the surface having thecathode collection element and thereby create a greater risk ofpolluting the cathode section with particulate contaminants. Thus, byemploying a cathode terminal at another surface than the surface havingthe cathode collection element the risk of contamination of the cathodesection with particles is minimised.

When the cathode collection element with the ventilation holes deviatesfrom a planar structure, the non-planar structure allows for a largeactive area in the same cross-section. In contrast, a planar cathodecollection element allows easier assembly of the DAFC of the inventionwith a microelectronic component and/or stacking with further DAFCs ofthe invention. In a specific embodiment the cathode collection elementand/or the anode collection element have a planar structure. It is to beunderstood in the context of the invention that when the structure of acollection element is described, this description refers to thestructure of the cathode collection element before mounting of the DAFCin a seating of a microelectronic component. The terminal siteselectrically connected to the collection elements provide appropriateelectrical connections between the terminal sites of the DAFC with thecorresponding terminals of the microelectronic component.

The collection elements may be made from any material or materials. Forexample, the collection elements may be made from metal. Alternatively,the collection elements may be made from a non-conducting material, e.g.a thermoplastic polymer, provided with a metallic coating or providedwith tracks, e.g. metallic tracks, which may be located on the surfaceof the polymer or in trenches in the polymer. In a preferred embodiment,the cathode collection element and the cathode terminal site are asingle piece, in particular a single piece of metal, e.g. stainlesssteel optionally coated with gold.

The collection elements may have any thickness as desired. For example,the thickness may be in the range of 10 μm to 2 mm, e.g. 50 μm to 500μm, e.g. about 100 μm. The collection elements may have a uniformthickness, or the collection elements may have different thicknesses. Itis also possible for each of the collection elements to have non-uniformthicknesses. In the context of the invention a “uniform thickness”refers to an average thickness with due consideration of naturalvariations in thickness due to manufacturing, use, etc. of thecollection element. For example, the uniform thickness may be an averagevalue plus or minus 20%.

In an embodiment the collection elements are each made from a singlepiece of material, in particular from a metallic material. The materialmay optionally be coated with a metal, and in the context of theinvention, a single piece of material coated with a metal, e.g. anothermetal, is still considered a single piece of material. It is especiallypreferred that the cathode collection element is made from a singlepiece of the metallic material, e.g. a single piece of metal, coatedwith another metal. Ductile metals may be used, but stiff metals areespecially preferred, since the cathode collection element may representan outer surface of the DAFC so that a stiff material better retains thestructure of the DAFC. Exemplary metallic materials comprise stainlesssteel, e.g. austenitic stainless steel, such as AISI 316L, nickel,silver, platinum or their alloys; or stainless steel, e.g. austeniticstainless steel, nickel, or their alloys, coated with a layer of gold orplatinum. A coating with another metal, e.g. gold or platinum, willtypically provide a layer of the other metal at a thickness in the rangeof 0.1 μm to 50 μm, e.g. 0.5 μm to 10 μm. When the cathode collectionelement and/or the anode collection element are made from a single pieceof material manufacture of the DAFC is simplified. Furthermore, thefeatures may be made smaller than what is possible when the sections aremade from different materials.

In a specific embodiment, the cathode collection element and itsterminal site are made from a single piece of metal, and the collectionelement and the terminal site have, independently, a thickness in therange of 50 μm to 500 μm, e.g. 100 μm to 300 μm. The same is relevantfor the anode collection element and its terminal site.

In a specific embodiment, the cathode collection element and/or theanode collection element is/are stamped, e.g. to its final shape, from asheet of an appropriate metal, e.g. stainless steel, such as austeniticstainless steel. The collection elements may subsequently be coated withanother metal, e.g. gold. In another embodiment, the cathode collectionelement and/or the anode collection element is cut from a metal plateusing any appropriate technology, e.g. using shears or laser. Thecollection elements may be coated with another metal, e.g. gold, aftercutting. In further embodiments the cathode collection element and/orthe anode collection element are shaped to provide specific functions.For example, the anode collection element may take the form of the innerhousing.

Coatings with gold and other noble metals provide efficient electricalcontact due to the noble nature of the metal, and such coatings alsoprovide corrosion resistance. However, corrosion resistance may also beobtained by specific treatment of the metal, in particular stainlesssteel.

The PEM separates the anode section from the cathode section, and ingeneral the PEM will prevent fluid communication between the anodesection and the cathode section, and the PEM may be considered to serveas a gasket. Any way of securing the PEM to the walls of the externalhousing or the anode cup may be used. The PEM thus has a side facing thefuel, i.e. the “anode section”, and a side facing the oxidant, i.e. the“cathode section”; the PEM may also be described as having an “anodeside”, i.e. the side facing the anode section, and a “cathode side”,i.e. the side facing the cathode section. The scale of a single DAFC isgenerally determined by the surface area of the PEM, e.g. at the anodeside and the cathode side. The surface area of the anode side of the PEMis typically equal to the surface area of the cathode side of the PEM,although structural features at the respective sides may createdifferences in the surface areas of the cathode side and the anode side.In the context of the invention, the surface area of the PEM is the“superficial surface area”, which does not take increases in surfacearea due to the surface structure into consideration. For example, thesuperficial surface area may be in the range of 0.05 cm² to 10 cm². ThePEM may have any shape desired. For example, the PEM may be square withdimensions of 2 mm×2 mm, 5 mm×5 mm, or 10 mm×10 mm, or the PEM may becircular with diameters of 2.5 mm, 5 mm or 10 mm. When a PEM cup isused, these dimensions are relevant for the bottom of the PEM cup. Otherrelevant shapes are rectangular, elliptical, polygonal, etc. When thePEM has a superficial surface area in the range of 0.1 cm² to 1 cm², theDAFC can typically provide a continuous power output of up to 30 mW withpeaks of 50 mW or more. For example, the continuous power output may bein the range of 10 mW to 25 mW. The voltage will typically be in therange of 0.1 V to 1 V, e.g. 200 mV to 600 mV, regardless of thesuperficial surface area of the PEM.

The cathode collection element generally has a bulk area correspondingto the area facing the cathode side of the PEM and an effective areacorresponding to the bulk area minus the total area of ventilationholes, if present. For example, the collection element may havedimensions providing a bulk area in the range of 0.05 cm² to 10 cm²,e.g. the collection element may have dimensions of 2 mm×2 mm, 5 mm×5 mm,or 10 mm×10 mm, or the collection element may be circular with diametersof 2.5 mm, 5 mm or 10 mm, or any combination of the dimensions.

The cathode collection element has ventilation holes, and likewise theoptional weld plate also has ventilation holes. The ventilation holesallow that the gaseous oxidant can enter into the DAFC and come intocontact with the cathode catalyst, and likewise the ventilation holesallow that the waste components can diffuse away from the DAFC. Theventilation holes typically have a total area in the range of 1% to 90%,e.g. from 5% to 50% or 10% to 50%, of the bulk area of the collectionelement. The same values are relevant for the weld plate. The total areaof the ventilation holes may also be referred to as the “ventilationarea”. The cathode collection element, and the optional weld plate, maycontain any number of ventilation holes as desired, but in general thenumber of ventilation holes is in the range of 4 to 20, e.g. 6 to 10,for a DAFC with a PEM having an area of about 1 cm². Thus, in anembodiment the cathode collection element has up to 15 ventilation holesper cm² of the PEM. The ventilation holes may have any shape as desired,and each ventilation hole may have an area, e.g. in the surface of thecollection element or the weld plate, in the range of 0.5 mm² to 5 mm².

The cathode collection element, the anode collection element or both ofthe anode collection element and the cathode collection element, maycomprise a bendable segment located between the collection element andthe terminal site; the bendable segment may have any length as desired.In the context of the invention, the length of the bendable segment isdefined by the distance between the collection element and the terminalsite. For example, the bendable segment may have a length, e.g. for aDAFC with a PEM having an area of about 1 cm², in the range of 0.5 mm to5 mm, e.g. between 1 mm and 2 mm. For DAFCs with larger PEMs the lengthof the bendable segment may be proportionally longer. Correspondingly,the cathode collection element may be considered to have a length in thedimension parallel with the length of the bendable segment, and a widthin the dimension axial to the length of the bendable segment. Thebendable segment also has a width in the dimension axial to the lengthof the bendable segment. The length of the cathode collection element istypically in the range of 5 mm to 25 mm. The width of the cathodecollection element, e.g. the width of the collection element, istypically in the range of 2 mm to 10 mm. The width of the bendablesegment is generally in the range of 0.5 mm to 2 mm. The terminal sitemay have a length in the range of 2 mm to 10 mm and a width in the rangeof 0.5 mm to 5 mm.

The DAFC of the invention comprises a “fuel supply”. The fuel supply maybe integrated with the DAFC so that the DAFC contains a fuel reservoir,e.g. in an external housing optionally also containing the power pack.Alternatively, the DAFC is in fluid communication with an externalreservoir via an appropriate conduit. Regardless of the location of thereservoir the DAFC may comprise conduits and ports between the fuelsupply and the anode section. When the DAFC, e.g. a DAFC with a PEMhaving an area of about 1 cm², has a reservoir, the reservoir willtypically have a volume in the range of 10 μL to 2 mL, e.g. 50 μL to 500μL, such as about 100 μL, about 200 μL, about 300 μL or about 400 μL.For DAFCs with larger PEMs the volume of the reservoir may beproportionally larger.

The DAFC, including the optional reservoir, may be integrated into amicroelectronic device, e.g. a hearing aid, or the DAFC may be aseparate unit for mounting in an appropriately designed seating. Forexample, the seating may have electrical terminals for establishingelectrical connection to the terminal sites of the DAFC when the DAFC ismounted in the seating. Regardless whether the DAFC is a separate unitor whether it is integrated into a microelectronic device, the DAFC maybe contained in an external housing. The external housing is generally aliquid tight container with appropriate openings for providing alcoholfuel and gaseous oxidant to the fuel cell components. In an embodiment,the external housing is made from an electrically non-conductingmaterial, e.g. a polymer, such as a thermoplastic polymer. In anotherembodiment, the external housing is made from a material in electricalconnection with the anode catalyst or cathode catalyst, e.g. in the formof an anode cup or a cathode cup, respectively. In this embodiment theexternal housing can be the anode terminal or the cathode terminal,respectively.

The external housing may fully enclose the fuel cell components, e.g.the power pack, or one or more of the fuel cell components may providean outer surface of the DAFC. For example, in an embodiment the cathodecollection element provides an outer surface, e.g. the “top”, of theDAFC.

The presence of a pervaporation membrane, in particular a negativelycharged pervaporation membrane, in the anode section as defined aboveadvantageously allows that the DAFC may be used with an alcohol fuel,e.g. methanol, at a concentration of at least 10 M, e.g. a concentrationin the range of 15 M to pure methanol, which in turn allows that thealcohol fuel is transported passively to the anode catalyst and the PEM.In particular, the pervaporation membrane allows that the fuel is puremethanol, i.e. corresponding to a “concentration” of 24.7 M. However, itis also possible for the DAFC to have a pump, e.g. an integratedmicropump, for transporting the alcohol fuel from the reservoir to theanode catalyst. Likewise, the gaseous oxidant is transported passivelyto the cathode catalyst and the PEM, although active transportation isalso contemplated. The DAFC can thus be used without actively pumpingthe alcohol fuel into the anode section. In the context of theinvention, “passive” means that alcohol fuel is not actively pumped intothe anode section. Thereby, the size of the DAFC can be kept minimal foreasy integration into microelectronic devices.

When the DAFC has an anode cup as defined above, a PEM cup and apervaporation membrane, e.g. with or without negative charges, the DAFCcan be operated passively and omnidirectionally without active pumpingof the alcohol fuel to the anode section, and in turn the volume of thepower pack can be kept so small that the DAFC can have a higher energydensity than a lithium ion battery.

In a further aspect, the invention relates to a microelectronic devicecomprising the DAFC of the invention. The microelectronic device may beany device requiring a power supply of up to 100 mW. A preferredmicroelectronic device is a hearing aid. Other relevant microelectronicdevices include smart watches, smart phones and the like. For example, amicroelectronic device may have a dimension limited in size to 10 mm,e.g. two dimensions may be limited to have a size up to 10 mm.

In a further aspect, the invention relates to a method of operating aDAFC. The method may employ any DAFC of the invention, and the DAFC maybe comprised in a microelectronic device. Thus, after providing theDAFC, e.g. in a microelectronic device, a fuel is supplied to the DAFC,e.g. by bringing the fuel into diffusive communication with the anodesection. The DAFC advantageously allows alcohol fuels of highconcentration to be oxidised in the DAFC, and the fuel may have amethanol concentration in water of at least 10 M, e.g. a concentrationof methanol in the range of 15 M to pure methanol. Thus, an aqueoussolution of methanol at a concentration of at least 10 M is supplied tothe DAFC.

All embodiments and variations, and their corresponding effects,described for the DAFC of the invention are equally relevant for themicroelectronic device and the method of the invention, and vice versa.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following the invention will be explained in greater detail withreference to the schematic drawings, in which

FIG. 1 shows an exploded drawing of fuel cell components of a directalcohol fuel cell (DAFC) of the invention;

FIG. 2 shows a top view of a power pack of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a direct alcohol fuel cell (DAFC), to amicroelectronic device and to a method of operating a DAFC of theinvention. The DAFC has a proton exchange membrane (PEM) separating ananode section from a cathode section, and the PEM is structured to havea bottom and walls extending from the bottom to a containment distanceinto the cathode section, and wherein the cathode catalyst is locatedwithin the containment distance from the bottom.

The DAFC of the present invention is especially suited for amicroelectronic device. The microelectronic device may be any electronicdevice requiring a power input up to 30 mW, e.g. in the range of 1 mW to10 mW. The microelectronic device may be any microelectronic device, buta preferred microelectronic device is a hearing aid.

The DAFC of the present invention may use any alcohol as fuel. Preferredfuels include methanol and ethanol. When the DAFC employs methanol as afuel it may also be referred to as a direct methanol fuel cell (DMFC).Correspondingly, the DAFC may be a direct ethanol fuel cell (DEFC). Thealcohol will typically be provided as an aqueous solution, and theconcentration of the alcohol may be chosen freely. Typicalconcentrations of methanol (in water) for DMFCs are in the range of 1 Mto 3 M, but in the DAFC of the present invention the cell design allowsa much higher concentration, i.e. up to pure methanol corresponding to24.7 M, and the concentration of methanol will typically be at least 5M, e.g. in the range of 10 M to 24.7 M, such as about 20 M. In a DAFCthe alcohol is gradually oxidised to eventually be converted to H₂O andCO₂ as waste products. Consequently, in the context of DAFCs theintermediary oxidation states from the alcohol to the final wasteproducts may also be employed as fuel, e.g. for a DMFC formaldehyde andformic acid may also be used as fuel.

The DAFC contains a proton exchange membrane (PEM). The PEM may also bereferred to as a polymer electrolyte membrane, and the two terms may beused interchangeably. At the PEM protons are supplied through acatalytic process of the fuel, and any material with this property maybe employed. Exemplary PEMs comprise the perfluorosulphonic acid ionomersold under the trade name Nafion (e.g. N1110 or Nafion 117) by DuPontwho developed it in the 1960s. Other examples of appropriate materialsemploy linear polymers, such as styrene, styrene-derivatives,poly(arylene ether)s, sulphonation of existing aromatic polymers,co-polymers from sulphonated monomers, poly(imide)s, altered backbonepolymers, poly-phosphazene. Yet other approaches have involved theintroduction of silica in polymer electrolyte membrane polymerformulations.

The DAFC contains catalysts in the anode section and in the cathodesection. The catalysts generally comprise a catalytic metal, e.g.platinum or platinum-ruthenium, on a support material, e.g. carbon, withelectron conductive properties. Appropriate metals for the anodecatalyst and the cathode catalyst are well-known to the skilled personwho can select the metals freely. Likewise, support materials may alsobe selected freely. For example, the catalyst may comprise particulate,e.g. nanoparticulate, carbon, with catalyst nanoparticles of platinum orplatinum-ruthenium. Appropriate catalysts structures, and theirmanufacture, for the DAFC are disclosed in WO 2014/005598. Anothercatalyst is known as Johnson Matthey HiSPEC 13100 which is platinum,nominally 70% on high surface area advanced carbon support.

The DAFC may contain other components as desired. For example, the DAFCmay employ water management layers, e.g. microporous structures, and gasdiffusion layers, e.g. a microporous layer on which the catalyticstructure may be situated, e.g. platinum on a carbon support, whichprovides the catalytic conversion of the fuel to an electrical current.Likewise, the DAFC may contain gaskets and the like for making the DAFCand its layers fluid tight and for providing electrical insulation atappropriate sites, e.g. between terminal sites.

An exploded drawing of fuel cell components is depicted in FIG. 1.Briefly summarised, FIG. 1 depicts an embodiment of the DAFC 1 of theinvention. The DAFC 1 has a PEM 2 separating the anode section from thecathode section. The anode section contains an anode collection element41 electrically connected to an anode catalyst layer 42. Between theanode collection element 41, which is shaped to be an inner housing byhaving a bottom 411 and walls 412 extending from the bottom 411 to alength sufficient to contain the anode section and also the cathodesection, and the anode catalyst layer 42 is a pervaporation membrane 44,a spacer insert layer 45 and an anode diffusion layer (or watermanagement layer) 43. The cathode section contains a cathode collectionelement 31 with ventilation holes 311 and electrically connected to acathode catalyst layer 32, and between the cathode collection element 31and the cathode catalyst layer 32 is a cathode diffusion layer (or watermanagement layer) 33. The cathode section further comprises anoleophobic filter 34, and it may additional comprise an anion-exchangemembrane (not shown). Finally, the DAFC 1 contains isolator 51, gasket52 and weld plate 50, that are used to assemble the DAFC 1. When theanode collection element 41, or anode cup 41, is finally assembled tocontain both the anode section and the cathode section, the assembly isthus a power pack for a fuel cell. The power pack may be inserted in anexternal housing 10. The external housing 10 has a fuel inlet 101, andthe anode cup 41, which has holes 413 providing fluid communication withthe fuel reservoir (not shown) in the external housing 10. Specifically,the external housing 10 is attached to the power pack to form thereservoir.

FIG. 2 shows a top view of the partly assembled power pack. The featuresshown in the embodiment in FIG. 1 and FIG. 2 are discussed moreelaborately below in Example 1.

EXAMPLES Example 1

In the embodiment depicted in FIG. 1, the inner housing is the anodecollection element 41. The anode collection element 41 may also bereferred to as an “anode cup”, and the term “anode cup” will also referto the inner housing when the inner housing is the anode collectionelement 41. Likewise, the reference numeral 41 also refers to the anodecup 41.

The anode collection element 41 is prepared from AISI 316L stainlesssteel. Specifically, a sheet of 0.2 mm stainless steel has been punchedto provide the anode cup so that the bottom 411 has an area of 8.35mm×4.80 mm corresponding to the size of the fuel cell components in theanode section. The anode cup 41 may be coated with gold. The anode cup41 has a height sufficient to house the anode section and also thecathode section as explained below.

The bottom 411 of the anode cup 41 has holes 413, e.g. 5 holes 413 of adiameter of about 500 μm that allow fluid communication across thebottom 411. Alternatively, the holes 413 may be in the range of 100 μmto 1500 μm.

A pervaporation membrane 44 of 8.35 mm×4.80 mm size and a thickness of150 μm is placed at the bottom 411 of the anode cup 41. Thepervaporation membrane 44 consists of a poly-tetrafluoroethylene (PTFE)backbone with perfluoroether pendant side chains terminated by sulphonicacid; an exemplary pervaporation membrane 44 is marketed by Solvay underthe trademark Aquivion E98-15S. The pervaporation membrane 44 allowsmethanol vapour to pass through from a liquid fuel so that thepervaporation membrane 44 provides pervaporative communication frombelow the anode cup 41 to the anode section. Furthermore, the negativecharges of the sulphonic acid groups provide a cation-exchange functionso that metal ions are sequestered from liquids diffusing into thepervaporation membrane 44, and thereby metal ion contamination of theDAFC 1 is avoided. However, the pervaporation membrane 44 may also be aPTFE backbone without charged groups. Such a pervaporation membrane 44prevents direct fluid communication from the fuel supply to the PEMwhile still allowing pervaporative communication, and thereby alsodiffusive communication. The distance from the PEM 2 to thepervaporation membrane 44 may also be referred to as the spacingdistance.

On top of the pervaporation membrane 44 is placed a spacer insert 45.The spacer insert 45 may also be referred to as a PM insert. The spacerinsert 45 has been prepared from a 100 μm sheet of AISI 316L stainlesssteel, and it has 5 holes 451, e.g. distributed as shown in FIG. 1, of1.2 mm diameter. The spacer insert 45 may be coated with gold, as isdone in the present embodiment. The spacer insert 45 improves theelectrical connection between the anode catalyst layer 42 and the anodecup 41, and the holes 451 allow access of the fuel, e.g. methanol, tothe anode catalyst 42 layer.

The distance between the PEM 2 and the spacer insert 45 is about 500 μm,and about halfway between the PEM 2 and the spacer insert 45 the wall412 of the anode cup 41 has, e.g. in the middle of the longer wallsection of the wall 412 of the anode cup 41, a venting hole 414 of adiameter of 50 μm. Specifically, the centre of the venting hole 414 isplaced at about 250 μm from the spacer insert 45 of the anode cup 41.The venting hole 414 allows vapour of H₂O and CO₂ produced in the DAFC 1to leave the anode section. When the diameter of the venting hole 414 isin the range of 25 μm to 300 μm, penetration of O₂ into the anodesection as well as fuel losses from the anode section are minimised.Thereby the venting hole 414 provides a more efficient DAFC 1.

On top of the spacer insert 45, i.e. relative to the bottom 411 of theanode cup 41, is placed an anode diffusion layer 43 (the diffusion layermay also be referred to as a water management layer). The anodediffusion layer 43 is a fibrous carbon material that is generally knownas carbon paper. The carbon fibre material may also have a microporouslayer of carbon particles and the carbon fibre substrate and/or themicroporous layer may have a hydrophobic, e.g. a PTFE-derivatised,treatment. Being fibrous, the anode diffusion layer 43 can be compressedbut its thickness in an uncompressed state is 250 μm, and furthermore,the fibrous material may be described with an area weight; anappropriate area weight is in the range of 120 g/m² to 150 g/m². Anexemplary fibrous material to use for the anode diffusion layer 43 ismarketed as H23C6 by Freudenberg.

The spacer insert 45 and the anode diffusion layer 43 have dimensioncorresponding to the bottom 411 of the anode cup 41, i.e. 8.35 mm×4.80mm, but the sizes of the spacer insert 45 and the anode diffusion layer43 are not critical and smaller dimension are also possible, e.g. to 80%of the dimensions of the bottom 411 of the anode cup 41.

The anode catalyst layer 42 and the cathode catalyst layer 32 eachcomprise a substrate carbon cloth and a layer of a support material withcatalytic metal nanoparticles; the support materials are carbon particlematerials with high specific surface areas. In this embodiment, theanode catalyst layer 42 and the cathode catalyst layer 32 may also bereferred to as gas diffusion electrodes. Thus, a gas diffusionelectrode, i.e. the anode catalyst layer 42, is then placed on top ofthe anode diffusion layer 43 relative to the bottom 411 of the anode cup41. The anode catalyst layer 42 is a carbon cloth substrate with a layerof carbon support with a high specific surface area carrying catalyticnanoparticles. For example, the carbon support may carry appropriatemetallic nanoparticles having a specific surface area of at least 50m²/g. A typical catalyst layer has about 20% to 80% by mass of metal tocarbon. The anode catalyst layer 42 has a mixture of platinum andruthenium as the catalytic metal. An appropriate anode catalyst materialis marketed by Johnson Matthey under the trademark HiSpec, e.g. HiSpec13100, HiSpec 12100, etc. The thickness of the anode catalyst layer 42in FIG. 1 is 500 μm to 600 μm when the anode catalyst layer 42 is in anuncompressed state. Of this value the catalyst layer is about 150 μm to250 μm.

The PEM 2 is placed on the anode catalyst layer 42. In this embodiment,the PEM 2 is structured to have a bottom 21 and walls 22 extending fromthe bottom 21 to a containment distance into the cathode section; thecontainment distance is sufficient to contain the cathode section. Inthis embodiment the PEM 2 may also be referred to as the PEM cup 2, andthe reference numeral 2 will also refer to the PEM cup 2. By having PEMcup 2 housing the cathode section, which in turn is housed in the anodecup 41, a very compact design of the DAFC 1 is obtained. Since the PEMcup 2 is contained in the anode cup 41, the area of the bottom 21 of thePEM cup 2 is correspondingly smaller. In the present embodiment, thebottom 21 has dimensions, i.e. dimensions inside the PEM cup 2, of 8.05mm×4.50 mm.

The PEM 2 may be made from any material allowing selectivetransportation of protons across the membrane. Typically, the PEM 2 ismade from a polymeric material having a PTFE backbone withperfluoroether pendant side chains terminated by sulphonic acid.Exemplary materials are marketed by Dupont under the trademark Nafion.In the embodiment depicted in FIG. 1, the PEM 2 is Nafion 117 with athickness of about 175 μm. The PEM cup 2 has been shaped, e.g.hot-pressed. from a single sheet of Nafion 117. Thereby, the PEM 2 canalso serve as a gasket to prevent undesired fluid communication to thecathode section and the area of the anode cup 41 is used moreefficiently so that a larger effective area is achieved.

A gas diffusion electrode, i.e. the cathode catalyst layer 32, is thenplaced in the PEM cup 2. The same materials as relevant for the anodecatalyst layer 42 are relevant also for the cathode catalyst layer 32.In the embodiment of FIG. 1, a HiSpec 13100 material is depositedtogether with Nafion on a carbon cloth and is cut to dimensions of 8.05mm×4.50 mm, and the thickness of the cathode electrode layer 32 is 450μm to 500 μm when the cathode catalyst layer 32 is in an uncompressedstate of which the catalyst layer is 100-150 μm.

A cathode diffusion layer 33 is placed on the cathode catalyst layer 32.As for the anode diffusion layer 43, the cathode diffusion layer 33 isalso H23C6, and the same materials are relevant for both diffusionlayers.

The cathode catalyst layer 32 and the cathode diffusion layer 33 areshown with an isolator 51 between them. In the embodiment of FIG. 1, theisolator 51 is made from the electrically insulating material KaptonHN500 (as marketed by Dupont). Kapton is a polyimide film, and anypolyimide film may be used for the isolator 51. The isolator 51 has athickness of about 50 μm, and in FIG. 1 the isolator 51 is shown with aflap 511 placed at an approximate right angle to the isolator 51. Uponassembly of the power pack the flap 511 will extend from the PEM cup 2and the anode cup 41 through cut-outs in the walls of PEM cup 2 and theanode cup 41. Thus, the wall 22 of the PEM cup 2 may have an opening221, e.g. a cut-out, and wall 412 of the anode cup 41 may have anopening 415, e.g. a cut-out; the openings are aligned to allow the flap511 to extend through them. After assembly the flap 511 may be placedalong the wall of the external housing 10, if used, or the anode cup 41in order to provide a site for a cathode terminal that is electricallyinsulated from the anode cup 41, including the bottom of the cut-out415.

The isolator 51 has a cut-out section allowing physical contact betweenthe cathode catalyst layer 32 and the cathode diffusion layer 33 overthe majority of the areas for the cathode catalyst layer 32 and thecathode diffusion layer 33.

A cathode collection element 31 with ventilation holes 311 is placed incontact with the cathode diffusion layer 33. The ventilation holes 311allow diffusion of gaseous oxidant to the PEM 2 and waste gasses awayfrom the PEM 2. The cathode collection element 31 has been stamped froma 200 μm sheet of AISI 316L stainless steel, which has subsequently beencoated with gold. The cathode collection element 31 is shown with 6ventilation holes 311 but fewer or more ventilation holes 311 may alsobe used. In the depicted embodiment, the ventilation holes 311 arerectangular with dimensions of 1.2 mm×0.9 mm.

The cathode collection element 31 has a cathode terminal site 312 shownat a right angle to the cathode collection element 31. The placement ofthe cathode terminal site 312 complies with the flap 511 of the isolator51, and the cathode terminal site 312 extends through the same cut-outsin the anode cup 41 and the PEM cup 2. After assembly of the power packthe cathode terminal site 312 may be bent at a bendable segment locatedbetween the cathode collection element 312 and the cathode terminal site312. In particular, the cathode terminal site 312 may be bent towardsthe anode cup 41 where the flap 511 of the isolator 51 ensures that thecathode terminal site 312 is electrically insulated from the anode cup41 and the corresponding anode terminal. Thereby, the cathode terminalsite 312 with the bendable segment allows a compact design of the powerpack and also the DAFC 1.

The part of the cathode collection element 31 located in the cathodesection has dimensions of 8.05 mm×4.50 mm, although it is not requiredto have the same dimensions as the bottom of the PEM cup 2; inparticular, the dimensions of the cathode collection element 31 locatedin the cathode section may be from 80% of the dimensions of the bottomof the PEM cup 2.

On the cathode collection element 31 is placed an oleophobic filter 34with dimensions of 8.05 mm×4.50 mm. The oleophobic filter 34 is anuncharged microporous PTFE membrane with a thickness of 180 μm and apore size of 0.4 μm. Specifically, the oleophobic filter 34 is a PMV15Tmembrane from Porex. The oleophobic filter 34 prevents penetration ofliquids into the cathode section while at the same time allowingpenetration of gasses, e.g. waste gasses from the DAFC 1 and gaseousoxidant into the cathode section. The oleophobic filter 34 furtherprovides electric insulation between the weld plate 50 and the cathodecollection element 31.

In FIG. 2, the oleophobic filter 34 is inserted in the anode cup 41, andFIG. 2 shows the cut-out 415 in the anode cup 41. The cathode terminal312 is shown extending from the anode cup 41 via the cut-out 415. Theembodiment of the oleophobic filter 34 depicted in FIG. 2 has 6 slits341 located so as to be aligned with the six ventilation holes 311 ofthe cathode collection element 31, which is located below the oleophobicfilter 34. The slits 341 are depicted as diagonal cuts for eachventilation hole 311. The slits 341 allow transfer of H₂O as liquid,through the oleophobic filter 34. However, the DAFC 1 will also functionwithout the slits 341.

The DAFC 1 further comprises an anion-exchange membrane (not shown)located between the cathode collection element 31 and the cathodediffusion layer 33. The anion-exchange membrane may be a fumapemFAA-3-30 membrane (Fumatech BWT GmBH, Bleitigheim-Bissingen, Germany).The anion-exchange membrane may alternatively be a hydrogel with aminegroups, in particular quaternary amine groups. The anion-exchange groupswill sequester negatively charged ions, in particular chloride ions,from liquids diffusing through the anion-exchange membrane. Thus, whenan anion-exchange membrane is employed the fuel cell interior, e.g. thecathode section, is protected from sweat. Thereby, the anion-exchangemembrane provides a power pack and a DAFC 1 especially suited for use ina hearing aid.

The power pack can now be finalised by welding a weld plate 50 with theanode cup 41 or the external housing 10. Thus, the weld plate 50, whichhas dimensions corresponding to the dimensions of the bottom of theanode cup 41 thereby allowing the enclosure of the anode section and thecathode section in the anode cup 41 is placed on top of the oleophobicfilter 34, and the weld plate 50 is then welded along the edge of theweld plate 50 to the wall of the anode cup 41. The weld plate 50 may beplaced in the anode cup 41 and welded to the inner wall of the anode cup41, or the weld plate 50 may be welded to the wall of the anode cup 41at the top of the anode cup 41. Thereby, it is ensured that the powerpack is as small as possible, which further optimises diffusion of fueland waste gasses to and from the PEM 2.

The weld plate 50 has ventilation holes 501, which will be aligned withthe ventilation holes 311 of the cathode collection element 31, andwhich have the same the same function as the ventilation holes 311, i.e.allowing diffusion of gaseous oxidant to the PEM 2 and waste gasses awayfrom the PEM 2. The weld plate 50 has been prepared from a 200 μm sheetof AISI 316L stainless steel. The weld plate 50 will generally not havea coating as it is not used as an electrical terminal, even though bywelding to the anode cup 41 any section of the weld plate 50 may serveas an anode terminal site.

The now assembled power pack has dimensions of 9.0 mm×5.5 mm×2.5 mm. Thefull outer surface of the anode cup 41 can serve as an anode terminalsite, and the power pack may have a cathode terminal site 312 extendingfrom the power pack so that the anode terminal site and the cathodeterminal site 312 may connect to corresponding terminal sites of anelectrical circuit.

The power pack, or the DAFC with the external housing, may comprise agasket 52, e.g. a silicone gasket, that electrically insulates the powerpack or DAFC for integration with an external microelectronic device;the gasket 52 further allows a fluid tight integration with the externalmicroelectronic device.

The power pack may be used as a DAFC with an appropriate fuel supply.However, in the embodiment depicted in FIG. 1, the power pack is placedin an external housing 10 so that the holes 413 in the anode cup 41 facea fuel reservoir contained in the external housing. The external housing10 can be considered to be the reservoir. In the embodiment of FIG. 1,the external housing 10, i.e. the fuel reservoir, is located below theanode section and the fuel is in fluid communication with the anodesection via the holes 413. The embodiment in FIG. 1 has a reservoir of avolume of about 200 μL.

As depicted in FIG. 1 the external housing 10 has been prepared from asheet of AISI 316L stainless steel, which has dimensions for the anodecup 41 to generally fit snugly onto the external housing 10 with dueconsideration for allowing access to the venting hole 414.Alternatively, the wall of the external housing 10 may have a hole (notshown) aligned with the venting hole 414 for allowing diffusion from theventing hole 414. In particular, a hole in the wall of the externalhousing 10 may be larger than the venting hole 414, since the effectsobtained with the venting hole 414 will not be jeopardised by the holein the wall in the external housing. Alternatively, the venting hole 414and the hole in the wall of the external housing 10 may be created afterfitting the anode cup 41 in the external housing 10, e.g. using laserablation or micro drilling etc.

The anode cup 41 and the external housing 10 may be welded or gluedtogether. The anode cup 41 could also be pressed against a gasket 52.Due to the close contact between the surfaces of the anode cup 41 andthe external housing 10, the outer surface of the external housing 10may provide an anode terminal site. The wall of the external housing 10may have a cut-out (not shown) through which the flap 511 and thecathode terminal site 312 can extend. The cathode terminal site 312 canthen be bent towards the wall of the external housing 10 with the flap511 providing electrical insulation between the external housing 10,i.e. the anode terminal site, and the cathode terminal site 312.Alternatively, the external housing 10 may be coated or otherwisecovered with an electrically insulating layer to prevent short-circuitsbetween the anode terminal site and the cathode terminal site 312; theanode terminal site may be exposed as desired by removing sections ofthe coating on the external housing 10.

The external housing 10 has a fuel inlet 101 for replenishing the fuelin the reservoir and removing spent fuel. The external housing 10 mayhave any appropriate valve or valves (not shown), and it may worktogether with an external supply of fuel employing an appropriate pump.

REFERENCE NUMERALS

-   -   1 Direct alcohol fuel cell (DAFC)    -   10 External housing    -   101 Fuel inlet    -   2 Proton exchange membrane (PEM)    -   21 Bottom of PEM    -   22 Walls of PEM    -   221 Opening in wall of PEM    -   31 Cathode collecting element    -   311 ventilation holes of cathode collecting element    -   312 Cathode terminal site    -   32 Cathode catalyst layer    -   33 Cathode diffusion layer    -   34 Oleophobic filter    -   341 Slit    -   41 Anode collecting element    -   411 Bottom of anode collecting element    -   412 Walls of anode collecting element    -   413 Hole in bottom of anode collecting element    -   414 Venting hole    -   415 Opening    -   42 Anode catalyst layer    -   43 Anode diffusion layer    -   44 Pervaporation membrane    -   45 Spacer insert layer    -   451 Hole of the spacer insert layer    -   50 Weld plate    -   501 Ventilation hole of weld plate    -   51 Isolator    -   511 Flap of isolator    -   52 Gasket

Although some embodiments have been described and shown in detail, theinvention is not restricted to them, but may also be embodied in otherways within the scope of the subject matter defined in the followingclaims. In particular, it is to be understood that other embodiments maybe utilised and structural and functional modifications may be madewithout departing from the scope of the present invention.

In device claims enumerating several means, several of these means canbe embodied by one and the same item of hardware. The mere fact thatcertain measures are recited in mutually different dependent claims ordescribed in different embodiments does not indicate that a combinationof these measures cannot be used to advantage.

It should be emphasized that the term “comprises/comprising” when usedin this specification is taken to specify the presence of statedfeatures, integers, steps or components but does not preclude thepresence or addition of one or more other features, integers, steps,components or groups thereof.

1. A direct alcohol fuel cell (DAFC) comprising a proton exchangemembrane (PEM) separating an anode section from a cathode section, whichcathode section contains a cathode collection element electricallyconnected to a cathode catalyst, the cathode catalyst being in diffusivecommunication with a gaseous oxidant, and which anode section comprisesan anode collection element electrically connected to an anode catalyst,the anode catalyst being in diffusive communication with a fuel supply,wherein the PEM is structured to have a bottom and walls extending fromthe bottom to a containment distance into the cathode section, andwherein the cathode catalyst is located within the containment distancefrom the bottom.
 2. The DAFC according to claim 1, wherein the cathodecollection element has a cathode terminal site, and the cathodecollection element with the cathode terminal site is made from a singlepiece, and the PEM has an opening through which the cathode terminalsite extends.
 3. The DAFC according to claim 1, wherein the PEM has beenmade using thermoforming and/or vacuum forming.
 4. A microelectronicdevice comprising a DAFC according to claim
 1. 5. A method of operatinga DAFC, the method comprising the steps of: providing a DAFC accordingto claim 1; supplying a fuel comprising an aqueous solution of methanolat a concentration of at least 10 M to the DAFC.